System and method for reprocessing animal bedding

ABSTRACT

A method and system reprocess soiled animal bedding material commingled with animal manure. In one aspect the soiled animal bedding material is separated in a shaker to send at least a preponderance of the manure to a holding tank. In another aspect the bedding is cleaned, rinsed and color is restored. The bedding material is subsequently dried and a bedding product, fertilizer product, and/or compacted product is formed. Alternatively, said bedding material is dried (without a compacting step) to form a product. In yet another aspect, the steps of separation, cleaning, rinsing and/or color restoration may be omitted.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of applicant's co-pending U.S. patentSer. No. 16/408,068 filed May 9, 2019 entitled “System and Method forReprocessing Animal Bedding” which, in turn, is a continuation of U.S.patent application Ser. No. 15/279,153 filed Sep. 28, 2016 entitled“System and Method for Reprocessing Animal Bedding,” now U.S. Pat. No.10,626,059 which, in turn, is a continuation in part of applicant's U.S.patent application Ser. No. 13/986,758 filed Jun. 3, 2013 entitled“System and Method for Reprocessing Animal Bedding,” now U.S. Pat. No.9,596,827 which, in turn, is a divisional of applicant's U.S. patentapplication Ser. No. 12/653,288 filed Dec. 11, 2009 entitled “System andMethod for Reprocessing Animal Bedding,” now U.S. Pat. No. 8,464,500which, in turn, claims the benefit of U.S. Provisional Application Ser.No. 61/154,697, filed Feb. 23, 2009, entitled “Recycled Animal BeddingWith A Chemical Process That Returns Them Back Very Close To TheOriginal State, And Creates A Bi-Product That Can Be Used AsFertilizer,” the disclosures of which are hereby incorporated in theirentirety by reference thereto.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to the reprocessing of animal beddingmaterial; and more particularly to a system and process for cleaning andsanitizing animal bedding material to remove animal waste productscommingled therein, permitting it to be reused as bedding or recycled asa raw material for producing other end-use products.

2. Description of Related Art

Domestic animals are widely kept by humans for pleasure, sport, or doinguseful work. These animals are often housed in stalls, pens, cages, orother confining enclosures in which a bedding material is disposed onthe floor to absorb the liquid and solid waste products of the animal.The absorbency of the bedding material reduces the animal's contact withthe waste, improving comfort and minimizing skin irritation and disease.Large animals, such as horses, produce proportionately large amounts ofwaste. For example, it is estimated that a typical horse weighing about1000 pounds may produce as much as about 30 pounds of feces and 2.5gallons of urine daily, for a total of some 50 pounds of total raw wasteper day. Soiled bedding removed with the manure during stall cleaningmay account for another 8 to 15 pounds per day of waste, resulting inabout 12 tons of waste a year per horse. Disposal of this matterpresents serious aesthetic issues and, more importantly, environmentalconcerns for air and water pollution if the waste enters surface bodiesof water or underground aquifers. The concerns are particularly acutefor farms or other facilities that house large numbers of horses orother large animals.

Conventional practice is that animal bedding is used once and thendiscarded. Costs, both for producing new bedding and for disposing itafter use, continue to increase. Most commonly, the materials used foranimal bedding are plant-based. For livestock such as cattle andpoultry, straw, hay, sawdust, kenaf, or wood shavings, or combinationsthereof, are typically used. Equine bedding typically includes pressedwood pellets, wood shavings, kenaf, or sawdust. With the decline inconstruction and in manufacture of wood based products there has been asignificant decline in the availability of wood pellets, shavings, andsawdust. As a result, bedding can be difficult to find and the cost hasincreased. Although certain synthetic, polymeric materials have beenproposed for bedding, they have not received widespread acceptance inthe agricultural community.

Along with the supply problems, costs for disposal have also increasedand available techniques are constrained by environmental concerns and,in some cases, by governmental regulations.

Current methods of disposal include: i) composting, ii) spreading onland as fertilizer, iii) stockpiling near the point of generation, andiv) landfilling. Although some benefits may be derived, each of thesesolutions entails significant difficulties and objections. Compostedmanure can be used as potting soil, but the process requires asignificant amount of land that is sufficiently isolated to prevent theinevitable odors from adversely impacting neighboring properties.Spreading the soiled bedding on land disperses both the waste materialand the sawdust, shavings, or the like that form the base of thebedding. While the waste gradually decomposes to provide nutrientscompatible with some crops, the concomitant bedding material causesdilution of the soil. As a result, dispersing the material is now beingscrutinized and may ultimately be banned. Stockpiling poses asubstantial risk that undesired substances may be leached into eitherunderground aquifers or surface bodies of water. In addition, odorsemanating a waste pile are objectionable. Landfill dumping incurssubstantial and increasing costs for transportation and land filloperation. Moreover, many landfills do not accept manure, as it caninterfere with the normal anaerobic decomposition processes if appliedimproperly or in excessive quantities. Governmental agencies arebecoming increasingly concerned about waste management, and thereforehave provided some funding through grants and low interest loans forlandfill diversion.

The few processes heretofore proposed for separating animal manure andrecycling used bedding are typically expensive and detrimentally alterthe physical structure and appearance of the material. Thus, they havenot been found satisfactory and readily accepted in the marketplace.

SUMMARY OF THE INVENTION

The present invention relates to the reprocessing of soiled animalbedding material. In various aspects, the invention provides a systemand process for treating soiled bedding material to remove animal wasteand provide material that can be recycled and either used again asbedding or further processed into other products.

In one aspect the soiled animal bedding material is separated in ashaker to send at least a preponderance of said manure to a holdingtank. In another aspect the bedding is cleaned, rinsed and color isrestored. Said bedding material is subsequently dried and a beddingproduct, fertilized product, and/or compacted product is formed.Alternatively, said bedding material is dried (without a compactingstep) to form a product. In another aspect, the steps of separation,cleaning, rinsing and/or color restoration may be omitted.

One aspect provides a process for reprocessing soiled animal beddingcommingled with manure or like animal waste products. The processcomprises in sequence the steps of:

-   -   a. separating said soiled bedding material in a first        shaker/screener to send at least a preponderance of said manure        to a holding tank and a remainder of said soiled bedding to a        second shaker/screener;    -   b. cleaning said soiled bedding in said second shaker/screener        using a first cleaning agent and transferring said soiled        bedding to a third shaker/screener;    -   c. rinsing said soiled bedding in said third shaker/screener        with first rinse for a first rinsing period and dewatering said        soiled bedding;    -   d. collecting waste water resulting from at least one of said        washing, rinsing, or draining steps; and    -   e. drying said bedding to form cleaned recycled bedding        material.        Steps a-d may be omitted. The process may include the step of        color restoration. Preferably, color restoration is applied        during said rinsing of said soiled bedding, however it can be        applied prior to drying. The color restoration may comprise        paint which, in turn, may include antimicrobial and antifungal        agents. Alternatively, the color restoration comprises a dye.        Preferably, the color restoration is a color selected from the        group consisting of white, cream, shades of beige, and blonde.        The color restoration may be comprised of a coloring selected        from the group of organic and non-organic pigments. Deodorizers,        antimicrobial and/or antifungal agents may be added. In a        preferred embodiment the cleaning agent comprises sodium        bicarbonate (baking soda). In another embodiment, vinegar and/or        lemon may be used in the process for cleaning and deodorizing        said bedding. Additives may be added to said bedding after said        bedding is dried. These additives may include one or more        deodorizers, and/or insect repellents selected from the group        consisting of citronella, lavender, and botanicals. The process        may include the step of addition of magnets and metal detectors        for removal and detection of ferrous and non-ferrous materials        in said bedding. Additionally, the process may include the step        of packaging the product. The packaging step is preferably        carried out by a bagging system configured to receive said        product and package it into bags.

The process preferably further includes the step of composting saidseparated manure. This can be done by compost bins for windrowing and/orusing an in-vessel compost system. In a preferred embodiment the beddingmaterial comprises wood shavings.

In another aspect of the process, the step of compacting said driedbedding material to form a compacted product is carried out, preferablyby press, and the compacted product is packaged, by, for example, abagging system configured to receive said compacted product and packageit into bags. The compacted product may be formed as pellets, which maybe used for burning or may be used for bedding. Alternatively, thecompacted product is formed as briquettes and/or manufactured logs.

Another aspect provides a process for reprocessing soiled animal beddingcommingled with manure or like animal waste products. The processcomprises in sequence the steps of:

-   -   a. decontaminating said soiled animal bedding material        commingled with manure by heating and drying said soiled animal        bedding material in a dryer; and    -   b. processing said bedding material to yield an end product.

The end product may be a fuel product (such as a briquette, manufacturedfire log, and pellets), fertilizer (log, pellets, composted manure),soil amendment product (log, pellets, composted manure), and/or abedding material (shavings, pellet). The process may include the step ofutilizing a grinder on said soiled animal bedding.

The process may include the following step prior to said decontaminationstep of subsection a: separating said soiled bedding material in a firstshaker/screener to send at least a preponderance of said manure to aholding tank and a remainder of said soiled bedding to a secondshaker/screener.

Additional steps, in sequence, may be implemented prior to saiddecontamination step of subsection a:

-   -   i. cleaning said soiled bedding in said second shaker/screener        using a first cleaning agent and transferring said soiled        bedding to a third shaker/screener;    -   ii. rinsing said soiled bedding in said third shaker/screener        with first rinse for a first rinsing period and dewatering said        soiled bedding; and    -   iii. collecting waste water resulting from at least one of said        washing, rinsing, or draining steps.        After said decontamination step of subsection “a” the following        steps may be carried out: grinding said bedding, compacting said        bedding to form a fuel product, and packaging said fuel product;        packaging said bedding.

Additives for aroma and/or flame height and color may be added.Representative additives that can be added include hickory, potpourriand/or waxes.

In another aspect, a system for reprocessing soiled animal beddingmaterial commingled with manure to form a compacted product is provided.The system comprises in sequence:

-   -   a. a first shaker/screener adapted to separate out at least a        preponderance of said manure from said bedding material;    -   b. a second shaker/screener for cleaning said soiled bedding        using a first cleaning agent;    -   c. a third shaker/screener for rinsing said soiled bedding for a        first rinsing period;    -   d. collecting waste water resulting from at least one of said        washing, rinsing, or draining steps in a tank; and    -   e. drying said bedding to form cleaned recycled bedding        material.

The process may further comprise one or more additional cycles ofwashing and rinsing and/or a bleaching cycle employing a bleachingsolution of water and a bleaching agent, and a rinse thereafter.

Thus cleaned, sanitized, and dried, the bedding material may be reusedfor bedding, and may be packaged, e.g. in bags.

It has been found that after a number of cycles of the present cleaningprocess, the bedding may no longer have a consistency and appearancethat is desirable in the marketplace for high-end bedding applications.By using the processed material as a fuel, the need for costly andenvironmentally acceptable disposal is obviated and the material'senergy content may be beneficially used, providing clear environmentalbenefits. The processed and decontaminated material is also usable as afeedstock for other applications.

Thus, in another aspect, soiled animal bedding is cleaned and furtherprocessed to form other byproducts. For example, the cleaned bedding canbe further processed and compressed into compacted shapes in the form ofpellets, briquettes, or other desired shapes. All these forms can beburned as fuel. Pellets additionally may be used as an alternate form ofanimal bedding. Similar techniques can also be used to form fire logs orfire starter logs for domestic use. As used herein, the term fire logrefers to a manufactured article sized and shaped to resemble a sectionof a conventional log appointed for domestic use as fuel in a fireplace,wood stove, or the like. A fire starter log is a smaller, manufacturedarticle also intended for domestic use and adapted to catch firereadily, thus facilitating the building of a fire using other fuels in afireplace, wood stove, or the like. Fire logs and fire starter logs areherein referred to collectively as manufactured logs. Processed,sanitized bedding can be used as feedstock for other applications aswell, such as particle board.

In most cases, bedding appointed for reuse must be bleached to give itthe desired appearance and color. On the other hand, appearance is atmost a minor issue for manufactured logs, as a dark color is ordinarilyacceptable. Thus, bleaching may not be required. The washing and rinsingsteps may also be omitted if the soiled bedding is destined formanufactured logs. The shaking operation removes most of the animalexcrement, and what remains can be adequately decontaminated by heatingand drying the bedding, e.g. in a rotary drum dryer, and with the logscompacted thereafter.

Optionally, suitable additives are included in the final manufacturedlog product, e.g. to give it desired appearance and mechanicalintegrity. The additives may also be selected to impart a pleasing aromaor to provide different colors in the flames as the product burns. Suchadditives may include, for example, wax and/or potpourri.

Optionally, the system includes a second cleaning tank so that twowashing steps can be carried out in sequence by transferring materialfrom the first cleaning tank to the second cleaning tank. The secondcleaning tank is configured to receive water from the water source andto discharge water through at least one drain. It comprises an agitatorconfigured to cause motion of bedding material within the secondcleaning tank.

In some embodiments, the system includes a packaging system, such as abagging system configured to receive the material after the cleaning anddrying operations and package it into bags for storage and distribution.Alternatively, the system includes a press configured to compact thecleaned material into a compacted product, such as pellets, briquettes,or manufactured logs.

The system also optionally includes one or more waste water holdingtanks that receive process water from one or more of the washing,rinsing, bleaching, and/or color restoration cycles. The water may thenbe processed for reuse.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more fully understood and further advantages willbecome apparent when reference is had to the following detaileddescription of the preferred embodiments of the invention and theaccompanying drawings, wherein like reference numeral denote similarelements throughout the several views and in which:

FIG. 1 is a schematic depiction of a process for recycling animalbedding material;

FIG. 2 is a schematic depiction of a process for recycling animalbedding material;

FIG. 3 is a schematic depiction of a process for recycling animalbedding material;

FIG. 4 is a schematic depiction of a process for recycling animalbedding material;

FIG. 5 is a schematic depiction of a process for recycling animalbedding material;

FIG. 6 is a front plan view of a processing assembly for recyclinganimal bedding material;

FIG. 7 is a side plan view of the processing assembly of FIG. 6 ; and

FIG. 8 is a schematic depiction of a processing assembly for recyclinganimal bedding material.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates one possible implementation of the present animalbedding reprocessing process, shown generally at 100. The process firstinvolves delivery of the soiled bedding material into a vessel or tank,such as a hopper and conveyor device 111. Soiled bedding herein refersto used bedding material that generally includes manure/fecal matter,urine, animal matter, hay, straw, and cellulose bedding material (i.e.wood shavings, such as shavings of pine or fir; and/or pelleted wood).Soiled bedding may include other extraneous particles including beddingalternatives, such as peat moss, shredded newspaper, rice hulls, wheatby-products, shredded phone books, hemp, shredded cardboard, andpelleted straw.

In the embodiment shown in FIG. 1 , from the hopper and conveyor device111 the soiled bedding combined with waste materials is conveyed to aseparator device, preferably being a first shaker/screener 112.Separation is carried out typically using a shaker/screener device thatshakes the soiled bedding to remove the fecal debris, and the shakeremploys a leaf-type vibrating screener. In most cases, bedding appointedfor reuse as bedding undergoes the separation step through the firstshaker/screener 112, however the separation is not required inasmuch asdecontamination has been found to be adequate to break-down fecal matterand pathogens through use of high temperatures during the drying step(discussed in more detail hereinafter)[See FIG. 2 , option #2]. Whenemployed, the shaking operation removes a preponderance of the fecalmatter/animal excrement, debris and hay/straw to separate out thecellulose bedding, such as shavings. What remains can be adequatelydecontaminated by heating and drying the bedding, e.g. in a rotary drumdryer. A magnet may be applied to remove metal mixed within the bedding,such as nails, horse shoes, etc.

The removal of the manure can be done by any suitable mechanism,including a gravity feed, a pneumatic system, or a conveyor beltarrangement. The removed manure can be composted to produce fertilizeror potting soil using known techniques via composting bin 120 forwindrowing, or for in-vessel composting. Manure is preferably sent forcomposting traditionally through windrowing or in areas with spaceconstraints, odor and pest concerns it is processed by in-vesselcomposting systems via composting bin 120. In-vessel material (manureand hay) is held at about 50 to 60% moisture at temperatures of about131-170 F for three (3) days to kill pathogens and weed seeds. Then thecompost material is removed to cool off for a period of about 10 to 12days, whereupon it may be bagged. Good procedures produce soilamendments that: (i) build soil reserves improving structure stability,and water-holding capabilities; (ii) increase water infiltration ratesand root penetration, decreasing extra energy for tillage; (iii)increase seedling ability to sprout; and (iv) stimulate and increasegrowth of soil microbial populations, and beneficial organisms, such asearth worms.

The optional shaker/screener 112 separator device employed in the firststep of the present process operates by sifting the bedding to separatesolid manure droppings from the soiled bedding. The incoming beddingpasses through one or more screens of the shaker device with the manuresent to manure holding tank or composting bin 120. The manure may beallowed to fall by gravity. Alternatively, a conveyor or other transportmeans may be used.

Tank 113 holds gray water or waste water generated during the process.Tank 113 is in line with DAF treatment tank 119 which, in turn, is inline with water holding tanks 114 a, 114 b that enable reuse of water.Chemical storage tanks 123 are provided for holdingchemicals/surfactants/dyes/colorings/DAF treatment chemicals/etc. usedthroughout the plant design process 100.

During separation by the first shaker/screener 112, the shavings/beddingmaterial fall to the bottom deck onto a second shaker/screener 115 wherethey are cleaned via sprayer shaker for washing. Bedding/shavings withat least a preponderance of the manure removed, then travel, e.g. usinga conveyor or gravity fall, to second shaker/screener 115 or vesselwherein the soiled bedding, which is now rendered as predominatelyshavings, or bedding material, undergoes cleaning. Secondshaker/screener 115 preferably is a sprayer shaker for the cleaningoperation. Cleaning is understood to mean washing with water, aqueoussolutions, surfactants, solvents, including dry cleaning, and/or othercleaning means. Preferably, washing comprises cleaning with asurfactant. Shaking during overhead spraying devices is preferably usedfor washing and/or cleaning of the bedding material/shavings.

After washing of the bedding material/shavings via secondshaker/screener 115, the bedding material/shavings travels, e.g. usingconveyor or via a tank having an auger and hatch opening, or via gravityfeed falling to a third shaker/screener 116 or vessel to undergo arinsing and color restoration cycle, and/or neutralizing. Thirdshaker/screener 116 also is preferably a sprayer shaker that sprayswater or liquid to rinse the bedding material/shavings. Colorrestoration is provided generally to enhance the appearance of thebedding material/shaving. Color restoration may include use of bleach,or dying agents. Bleaching operation is optionally included in theprocess, either as a discrete step, as part of the rinsing step, or aspart of at least one of the washing steps. For the latter, the washingor rinsing solution may include a bleaching agent in addition to waterand some surfactant. Preferred bleaching agents includechlorine-containing agents, such as chlorine gas, chlorine dioxide, orsodium hypochlorite. Preferably, bleaching is carried out in a separatebleaching step by soaking the bedding in a chlorine-containing bleachingsolution, and thereafter rinsing the bedding with water. Preferably,bleaching is carried out after at least one washing cycle, and mostpreferably after all washing steps are completed. The concentration andtype of bleaching agent used are selected to achieve the desired levelof restored coloration to the bedding, without causing breakdown of thestructural integrity of the shavings or like bedding material. Thepresent system preferably comprises a bleaching agent dispenser adaptedto dispense a preselected amount of a bleaching agent into the firstcleaning tank.

During the rinse cycle via spray shaker/third shaker 116, turf paint orfood dye may be added in the water for dying the beddingmaterial/shavings. The color preferred is white, however all othercolors are contemplated as well. White, cream and shades of beige,blonde are the most preferred color spectrums so that the recycledbedding material/shavings most closely resemble unused beddingmaterials. The dye, paint, coloring (organic, non-organic, pigments) areadded preferably during the rinse cycle, however they may be addedduring the wash cycle, and/or rinse and wash cycles combined. There maybe more than one washing and/or rinsing cycle. After the washingcycle(s) and rinsing cycle(s) in the shakers, 115, 116, the beddingmaterial/shavings are dewatered to lower the moisture content. Followingdewatering, the bedding material/shavings are transferred to dryer 117which preferably uses a rotary drum and high heat temperatures fordrying and removing moisture and to further decontaminate the beddingmaterial/shavings.

The colorant may be dry applied in some instances or separately beforeentering the dryer 117. The ratios of dye vary according to the amountof coverage and opacity desired. Potassium Sorbate may be added forantimicrobial and fungicide properties, and or combinations orstand-alone antimicrobial and antifungal agents. Antimicrobial andantifungal agents may be added in the paint or separately. The infusionof deodorizers, antimicrobial and antifungal agents may be added in thewashing, rinsing, washing and rinsing, into the dye itself, or dryapplied before the final product is dried or added after the product isdyed. Baking soda, vinegar may be used in the washing, rinsing, and/orwashing and rinsing cycles for cleaning, deodorizing of bedding. Lemonmay be included as well for cleaning and/or deodorizing of the bedding.Baking soda may be added to the dried bedding product for odor control.Insect repellents, citronella, lavender, botanical may be added.Chemicals in washing, rinsing, or washing and rinsing, or dry appliedprior, during and/or after drying or any of the combinations may beadded. Addition of magnets and metal detectors may be provided forremoval and detection of ferrous and non-ferrous materials, i.e. horseshoe nails, needles. Holding tanks are not necessary, as the process canbe carried out without holding tanks.

After residence in the dryer 117, the recycled bedding material/shavingsare packaged or bagged using a bagger 118, or alternatively are placedas bulk bedding material/shavings appointed for hauling and transportfor use. The moisture content of the bedding material/shavings forbagging is up to about 17%; more preferably the moisture content is upto about 16%. It has been found that moisture levels higher than about17% lead to mold and microbial generation and, if stored for a period oftime spontaneous combustion. Moisture contents on the low spectrum,lower than 16%, are primarily driven by savings in time and cost ofdrying, and by industry standards, but could be as low as less thanabout 1% moisture. Optimal moisture content required to prevent mold andmildew ranges from about 10 to 17%, preferably 12 to 17%, and mostpreferably from about 14 to 16%. Preferably a vertical bagger is used,such as that sold under the trade name RethPACK VC-3030. The plantdesign process 100 also includes fuel containment tank(s) 124 and agenerator 125 for powering the process. Solar power may be employed, orgeopower, to further contribute to the environmentally sound process.The subject process provides a full loop environmentally green process.

Tank 113 holds gray water or waste water generated during the process.Waste from tank 113 is preferably treated by dissolved air flotation(DAF) 119 water treatment process to clarify the wastewaters by theremoval of suspended matter such as oil or solids. The removal isachieved by dissolving air in the water or wastewater under pressure andthen releasing the air at atmospheric pressure in a flotation tankbasin. The released air forms tiny bubbles which adhere to the suspendedmatter causing the suspended matter to float to the surface of the waterwhere it may then be removed by a skimming device. Dissolved airflotation is very widely used in treating the industrial wastewatereffluents from oil refineries, petrochemical and chemical plants,natural gas processing plants, paper mills, general water treatment andsimilar industrial facilities. A very similar process known as inducedgas flotation may alternatively be used for the wastewater treatment.Generally, DAF systems can be categorized as circular (more efficient)and rectangular (more residence time). The former type requires just 3minutes; an example is a Wockoliver DAF system. The rectangular typerequires 20 to 30 minutes; a typical example is a Syskill DAF system.One of the bigger advantages of the circular type is its spiral scoop.Treated waste water is housed in tanks 114 a, 114 b for reuse.

Combined waste material, including combined manure and/or manure andhay, straw, shavings, may be recycled and cleaned to yield bedding forpackaging or bulk loading reuse, composting of manure and other wastematerials, and/or packaging or compacting of waste material and/orcellulose bedding to form end use products, such as kindling, pellets,fire logs and/or briquettes. The process provides for the separation ofsoiled bedding comingled with manure, waste, hay and shavings, oralternatively the separation can be omitted. Where the manure isseparated from the bedding, it is appointed to undergo composting andthe bedding material can then be washed (or washing skipped), dried toyield recycled bedding material and/or subject to compacting to providefuel products and organic compost. Alternatively, the combined wastematerial does not undergo separation and is used to produce fuelproducts.

Hammering and grinding to compose materials into smaller uniformparticles may be carried out before drying or after drying thematerials, separated and/or unseparated. Separated and/or unseparatedmaterials may proceed to the grinder or dryer in different sequences.For example, materials are dried and then subjected to a grinder to beground/hammered for uniformity prior to compressing into fire logs,briquettes, pellets and/or fire starters. Alternatively, materials aresubjected to the grinder to be ground/hammered and then dried prior tocompressing into fire logs, briquettes, pellets and/or fire starters.Commingling of the soiled bedding with manure is preferably utilized forproducing the recycled bedding material, and/or fuel products. Whereinsoiled bedding with manure is not separated and the object is to renderrecycled bedding material (i.e. recycled shavings), optionally thebedding material may be subject to washing, cleaning and/or drycleaning, and rinsed as necessary, and then subject to high heat fordrying and decontamination of any residual fecal matter. Alternatively,wherein the soiled bedding is not separated and the object is to renderrecycled bedding material (i.e. recycled shavings) the bedding materialis not washed or cleaned (i.e. no washing, cleaning, dry cleaning, orrinsing step) and the bedding material with comingled manure is directlysubjected to the dryer for decontaminated and drying/removal of moistureas discussed herein. Where the soiled bedding comingled with manure andhay is appointed for use in generating fuel products, such as kindling,pellets or fire logs, the process preferably skips separation, washing,cleaning, and/or rinsing and is subjected to drying (and/or grinding).Wrapper and accelerant are preferably added to the covering/packaging ofthe fire logs, briquettes, fire starters. Brown paper wrappers arepreferably utilized for the fire logs. Paper cups are preferablyutilized for the fire starters. A layer of accelerant may be applied onthe fire starters. Additives such as hickory, mesquite and other flavorenhancements may be added for cooking over and/or combinations of two ormore enhancements may be added in the fire/wood pellets, logs andbriquettes.

FIG. 2 illustrates another possible implementation of the present animalbedding reprocessing process, shown generally at 200. FIG. 2 includes aplant design having at least three main options #1-3 discussed hereinbellow that depend on the end product sought. Option #1 is a process forend product recycled bedding material or shavings (but could be utilizedfor fuel products, though not recommended as it includes several stepsthat are not deemed necessary for the fuel product finished product) andincludes separation (optional), cleaning, rinsing and color restoration,drying, optional bagging for recycled bedding shavings, or optionalgrinding, bagging, and/or compacting for fuel products. Option #2 isanother process for end product recycled bedding material or shavingswherein option #1 is carried out but the separation, washing, andrinsing steps are omitted, relying on the high temperature fordecontamination of the fecal matter and pathogens. Option #3 is apreferred process for end product fuel products (kindling, briquettes,fire logs, pellets, etc.) and is carried out by omitting the separation,washing, and rinsing and color restoration steps. Each of the processoptions are discussed in detail herein below.

FIG. 2 , option #1 provides a process for yielding recycled beddingmaterial/recycled shavings:

Step 1: delivery of the soiled bedding material into a vessel or tank,such as a hopper and conveyor device 211 in line with a shakerseparator.

Step 2: the soiled bedding combined with waste materials is deliveredfrom the hopper and conveyor device 211 to a separator device, herein afirst shaker/screener 212. However, the separation is optional and maybe omitted. It is noted that, wherein the end product is to yield highend recycled bedding material/recycled shavings to be used in beddingthe separation step is preferably carried out. Although, even whereinthe end product is bedding, as discussed herein regarding option #2, theseparation, washing, and rinsing and color restoration steps may beomitted and decontamination achieved through washing, rinsing and/ordrying alone.

Step 3: the shavings/bedding material fall to the bottom deck onto asecond shaker/screener 215 for cleaning by way of overhead pressurespray. Tank 213 holds gray water or waste water generated during theprocess. The removed manure and hay can be composted to producefertilizer or potting soil using known techniques via compostingbin/in-vessel composting system 220. Cleaning involves washing theshavings/bedding material with water, water+bleach, aqueous solutions,surfactants, solvents (including dry cleaning technology, utilizinggreen dry cleaning chemicals and technology, and vapors. Preferably,washing is carried out using an aqueous solution with surfactant.

Step 4: after washing of the bedding material/shavings via secondshaker/sprayer shaker 215 the bedding material/shavings travels, e.g.using conveyor or via a tank having an auger and hatch opening, or viagravity fall to a third shaker/screener 216 or vessel/tank to undergo arinsing and color restoration cycle, and/or neutralizing. This ispreferably carried out by way of an overhead high pressure sprayer unitwhile the bedding material vibrates or shakes. After washing and rinsingcycles, 215, 216, the bedding material/shavings are dewatered to lowerthe moisture content. It is noted that there may be more than onewashing and/or rinsing cycle.

Step 5: the bedding material/shavings are transferred to dryer 217. Fromdryer 217 the bedding material/shavings may be bagged at 218 orotherwise piled for bulk use. Wherein the bedding material/shavings areappointed to be processed as fuel products, the bedding may be subjectedto grinder 221 at Step 6 b, then compacted via Briquette, Log orPelletizer 222 at Step 7, or directly compacted at Step 7, and packaged226 at Step 8.

Step 6 a: the recycled cleaned bedding material/recycled shavings arebagged 218 or otherwise provided as bulk for hauling and transport.

It is noted that tank 213 is in line with DAF treatment tank 219, whichin turn is in line with water holding tanks 214 a, 214 b that enablereuse of water.

Alternatively, another process for yielding recycled beddingmaterial/recycled shavings includes as option #2, omitting several ofthe steps above in option #1.

Option #2 is another process for end product recycled bedding materialor shavings wherein option #1 is carried out but the separation,washing, and rinsing steps are omitted, relying on the high temperaturefor decontamination of the fecal matter and pathogens.

Step 1 (option #2): delivery of the combined soiled bedding materialinto a vessel or tank, such as a hopper and conveyor device 211′. It isnoted that in FIG. 2 hopper and conveyor device 211′ is shown as aseparate hopper from 211, the hoppers (211 and 211′). Conversely, thehoppers (211 and 211′) may be the same hopper and conveyor and theequipment concerning the omitted steps are simply bi-passed.

Step 2 (option #2): the combined soiled bedding material is conveyeddirectly to dryer 217.

Step 3 (option #2): the bedding material is bagged 218 or bulk piled forhauling.

Option #3 is a preferred process for end product fuel products(kindling, briquettes, fire logs, pellets, etc.) and is carried out byomitting the separation, washing, and rinsing and color restorationsteps. Preferably, option #3 is carried out when the end product is tobe a fuel product produced from the soiled bedding material. Thefollowing steps in FIG. 2 are taken;

Step 1 (option #3): delivery of the soiled bedding material into avessel or tank, such as a hopper and conveyor device 211′.

Step 2 (option #3): the combined soiled bedding material may be conveyedto: i) grinder 221 and then to the dryer 217, ii) dryer 217 and thendirectly to packaging via bagger 218 or compacting into briquette, logs,pellets at 222 followed by packaging 226; iii) dryer 217 and then thegrinder 221 and then to compacting to form briquettes, logs orpelletizer 222 followed by packaging 226.

Step 3 (option #2): the recycled bedding material is bagged 218 orcompacting into briquette, logs, pellets at 222 followed by packaging226 as discussed in step 2 above to yield fuel products.

FIG. 3 is a schematic depiction of a process for recycling animalbedding material, shown generally at 300 in the formation of fuelproducts. The soiled bedding material/combined waste materials are fedinto a hopper and conveyor device 311 in line with a shaker separator312. The soiled bedding material/combined waste materials are optionallyfed to a first shaker/screener 312 for separation of bedding materialfrom manure, debris and hay, etc. Alternatively, the separation step canbe omitted and decontamination achieved through drying at high heat asdiscussed herein. Next, the combined soiled bedding material may beconveyed to: i) grinder 321 and then to the dryer 317 followed bycompacting into briquette, logs, pellets at 322 followed by packaging326; or ii) dryer 317 and then directly to compacting into briquette,logs, pellets at 322 followed by packaging 326; or iii) dryer 317 andthen the grinder 321, back through the dryer 317 and then compactinginto briquette, logs, pellets at 322 followed by packaging 326.Alternatively, the soiled bedding material/combined waste materials arefed into a hopper and conveyor device 311′. The separation step isomitted and decontamination achieved through drying at high heat asdiscussed herein. Next, the combined soiled bedding material may beconveyed to: i) grinder 321 and then to the dryer 317 followed bycompacting into briquette, logs, pellets at 322 followed by packaging326; or ii) dryer 317 and then directly to compacting into briquettes,logs, pellets at 322 followed by packaging 326; or iii) dryer 317 andthen the grinder 321, back through the dryer 317 and then compactinginto briquettes, logs, pellets at 322 followed by packaging 326.

FIG. 4 is a schematic depiction of a process for recycling animalbedding material, shown generally at 400 in the formation of fuelproducts. In this alternative embodiment, the soiled beddingmaterial/combined waste materials are fed into a hopper and conveyordevice 411 that is in-line with a shaker separator 412 that may beoptionally bi-passed to omit the shaking step (not in FIG. 3 aboveseparate hoppers, 311 and 311′ were provided in that plant design). Thesoiled bedding material/combined waste materials are optionallyseparated using a first shaker/screener separator 412. Alternatively,the separation step can be omitted and decontamination achieved throughdrying at high heat as discussed herein. Next, the combined soiledbedding material may be conveyed to: i) grinder 421 and then to thedryer 417 followed by compacting into briquette, logs, pellets at 422followed by packaging 426; or ii) dryer 417 and then directly tocompacting into briquette, logs, pellets at 422 followed by packaging426; or iii) dryer 417 and then the grinder 421, back through the dryer417 and then compacting into briquettes, logs, pellets at 422 followedby packaging 426.

FIG. 5 illustrates another possible implementation of the present animalbedding reprocessing process, shown generally at 10. The process firstinvolves separating soiled bedding and manure in a hopper with shakerdevice 11. Preferably, separation is achieved by shaking the soiledbedding to remove the fecal debris, and the shaker employs a leaf-typevibrating screener. Upon separation, the manure is removed to manuretank 12. The removal can be done by any suitable mechanism, including agravity feed, a pneumatic system, or a conveyor belt arrangement. Theremoved manure can be composted to produce fertilizer or potting soilusing known techniques.

The shaker usually employed in the first step of the present processoperates by sifting the bedding to separate solid manure droppings fromthe soiled bedding. The incoming bedding passes through one or morescreens of the shaker device with the manure sent to a holding tank 12.The manure may be allowed to fall by gravity, or a conveyor or othertransport means may be used. Soiled bedding with at least apreponderance of the manure removed, then travels, e.g. using aconveyor, to tank or shaker 13 for cleaning.

One form of shaker useful in carrying out the separation of manure frombedding comprises a plurality of vibrating, parallel bars, rods, ortines inclined at a slight angle to the horizontal. Bedding to beseparated is placed atop the bars, which are spaced apart by a distancethat permits shavings or the like, but not pieces of the animalexcrement, to fall between them into a collection system. Theinclination and vibrating action of the bars urges the manure to migratedownward into a holding bin, yielding an efficient separation withminimal loss of soiled bedding. One useful configuration of such aseparator is disclosed in U.S. Pat. No. 5,927,513 to Hart.

The present shaker is readily assembled using components such assifters, vibrating screeners, shakers, linear screeners, separators andprocessing equipment available from vendors such as Smico and Triflo,that currently serve the bulk material handling industries.

Soiled bedding is transferred from the shaker system into cleaningtank/shaker 13, wherein it is treated with cleaning products and rinsedwith water, preferable while undergoing slow agitation. For example, theagitation may be provided by an overhead rotary impeller. When used toprocess bedding material that is appointed for reuse, a relativelygentle agitation should be used to prevent over manipulation andbreakage of the bedding material. Preferably, the washing is carried outwith a ratio of a volume of water used to a volume of soiled beddingbeing at least 1:1. More preferably the ratio is at least 2:1, and evenmore preferably, at least 3:1. It is preferred that the water furtherinclude a detergent, soap, or other cleaning agent, such as at least onetablespoon of a domestic laundry detergent per gallon of soiled bedding,and more preferably at least two tablespoons per gallon. The presentsystem preferably includes a cleaning agent dispenser adapted todispense a preselected amount of a cleaning agent into the firstcleaning tank. Rinsing is preferably carried out with a ratio of avolume of water used to a volume of soiled bedding of at least 1:1 and,more preferably, at least 2:1. Tank 13, as well as all other tanks inthe system, preferably includes one or more drains from which liquid canbe removed as needed, either by gravity or by active means such aspumps. Preferably, tank 13 is cylindrical or frustoconical in shape topermit it to act in the manner of a large washing machine vat. Tank 13can be oriented with its cylindrical axis either vertical or horizontal.In some implementations, tank 13 can be spun rapidly to facilitatecentrifugal extraction of liquid at the end of each liquid cycle. Inother implementations, a compression device is present and used tosqueeze the contents for tank 13 to remove liquids. As anotheralternative, the bedding being cleaned is transferred after drainingfrom the cleaning tank to a separate dewatering apparatus, whichextracts more liquid by centrifugal or compressive action. Suitablesystems for carrying out the dewatering include those sold by TheSchlueter Company, Janesville, Wis.

Preferably, all the used liquids from the cleaning, rinsing, andbleaching cycles of the present process are collected in one or morewastewater holding tanks. Although the water may be discharged, possiblyafter remediation needed to comply with environmental requirements,preferably it is recycled to be used in one or more steps of the presentprocess.

Tank 13 further includes an optional hatch at its bottom that can beopened at the end of the cleaning and rinse cycles to allow the materialto be removed for drying. For example, material may be directed ontoconveyors carrying the material to the drying apparatus 16.

Prior to travel to drying apparatus 16, the bedding material is rinsedand subject to color restoration at 18. After/before drying the beddingmaterial may be subject to grinding 21 and/or directly compacted intobriquettes, logs or pellets 22 and packaged 26 for fuel products.

Preferably, a rotary drum drying machine is used to dry the beddingmaterial after it is cleaned and decontaminated, but any suitable dryercapable of reaching the temperature needed to remove moisture and assurethat any remaining pathogens are destroyed may also be used, forexample, a grain bin with augers. At least part of the fuel for the drumor other type dryer can be provided from the bedding itself, includingfines collected during the processing of the bedding. As anotheralternative, a continuous belt-type dryer carrying the material througha heated zone may be used. The heat source may be of any type, includingheat from combustion of a fuel, resistive heating, or infrared lamps.Microwave heating may also be used. Suitable rotary drum dryers includethose sold by Energy Unlimited Inc. for manufacturing wood shavings.Fuel feeder units and burners/solid fuel combustion systems/bio massburners may be used, such as those sold by Jackson Lumber Harvester,Mondovi, Wis., under the trade name Webb Burner™, or by EnergyUnlimited, Inc, Dodgeville, Wis.

The drying is typically carried out by placing the cleaned beddingmaterial in a dryer held at temperatures of at least about 300-350° F.,and preferably at about 600-800° F. The material is held at temperaturein the dryer for a time sufficient to attain a required moisture leveland to kill any remaining pathogens. At 600-800° F., the drying canoften be accomplished in a matter of two to four minutes. After thereprocessed bedding is dried to a desired moisture level, thereprocessed, clean bedding is bagged or otherwise packaged at 17.Typically, wood shavings are dried to a moisture level up to about 17%;more preferably the moisture content is up to about 16%; preferablymoisture ranges from about 10 to 17%, more preferably 12 to 17%, andmost preferably from about 14 to 16% for reuse as bedding to inhibitformation of mold or mildew. The bagging step at 17 is optionallyomitted if the reprocessed bedding is to be sold in bulk form.

As previously noted, the present system and method are primarilyintended for reprocessing bedding material so it can be reused for thesame purpose. However, other end uses are also possible. For example,after a number of reprocessing cycles, the physical character andappearance bedding may deteriorate. However, such clean reprocessedbedding material is still useful for other applications. It may becompacted using a suitable press or like apparatus into the form ofpellets, briquettes, or other articles such as manufactured logs. Thepellet form can be also used as bedding, or it can be directly burned asfuel. Shavings intended to be compacted are typically dried to amoisture level ranging from about 5 to 10%, preferably 6 to 9%, and mostpreferably 8 to 9%, to promote good coherence of the material in thecompacted form. Presses suitable for producing briquettes from cleanedbedding include those manufactured by Biomass Briquette Systems, LLC,Chico, Calif.

Separation of the manure and debris from the soiled bedding prior towashing can optionally be skipped and the soiled bedding with fecalmatter and debris can go directly to cleaning tank 13 for processing.However, separation of the fecal matter mitigates contamination of theprocess water and allows for a marketable byproduct, e.g. as fertilizeror compost.

In some instances, multiple cleaning cycles are optionally employed.They may be carried out serially in a single tank or, alternatively, ina semi-continuous process using separate cleaning tanks for differentcycles, with material being transferred from one tank to the next aftereach step. The cleaning products and water rinse beneficially improvethe cleaning of the soiled bedding, substantially eliminate smell, andrestore color.

It is preferred that the soiled bedding not be packed too tightly in thecleaning tank 13, lest the cleaning of the bedding is compromised.Instead, cleaning is best achieved if the bedding material is able tomove around and circulate in the cleaning tank 13 during the washing,rinsing, and optional bleaching operations. Whatever material remains inthe bedding after the cleaning operation is substantially non-toxic andclean. Too much material in the dryer makes it is difficult to achieveuniform drying in a reasonable time. The temperature actually attainedin the bedding during the cleaning and drying steps is preferablysufficient to ensure that any feces remaining in the bedding breaks downand any pathogens are killed, without charring, discoloring, orotherwise damaging the bedding.

The cleaning agents used in the one or more washing steps may includeone or more of conventional soaps, detergents (such as those used fordomestic laundering), or other suitable surfactants. Further additivesmay be used, such as alcohol, sodium bicarbonate, or sodium carbonate.Green soaps may be used as the cleaning products to provide even moreenhanced environmental benefits to the process as waste from the processitself would be minimized and/or environmentally friendly. The washingand cleaning equipment may include tanks having capacities ranging fromsmall quantities up to over 50,000 gallons of materials, such as thoseoffered for sale by Pittsburgh Tank & Power Company. Preferably, thetank 13 is implemented with an agitator and centrifuge machinery toclean and dewater the solid material. The agitating equipment aids inthe cleaning process. Suitable impeller systems and blades are availablein various RPM motor speeds, and are offered for sale, e.g. by Triflo.The cleaning tank 13 preferably acts as a large washing machine withmaterial being transferred into and out of the tanks by conveyor belts,pneumatic systems, loading equipment, or the like. A conveyer with sidesis preferred to be used in the process to avoid spillage of the beddingmaterial or loss of bedding material during conveying.

One particularly efficacious cleaning detergent that may be used is soldunder the trade name SA8 Bio Quest laundry detergent. Other chemicalscan be used, such as alcohol, hydrogen peroxide, PineSol® cleaner,OxyClean® powder, and any laundering, dishwashing detergent, soap nutsor magnetic laundering device. The washing, rinsing, and bleachingprocess steps may be carried out in vats or laundering machines, textilelaundering machines. Drying may be accomplished using any suitablesource of heat, such as a bin with a device such as an auger system toturn the contents during the heat drying.

The preferred duration of the washing cycle and whether a second washingcycle is needed, depends, in part, on the intended use of the cleanedbedding. For material appointed to be recycled as bedding, a secondcycle and longer duration are preferred to provide material withsubstantially the same color and appearance as raw bedding. Inclusion ofa bleaching cycle is also preferred to further enhance appearance. Onthe other hand, color and appearance are less critical for material tobe formed into pellets, briquettes, or logs for fuel, so that only asingle short cycle is needed to substantially remove all vestiges of theanimal waste.

A bleaching operation is optionally included in the process, either as adiscrete step or as part of at least one of the washing steps. For thelatter, the washing or rinsing solution may include a bleaching agent inaddition to water and some surfactant. Preferred bleaching agentsinclude chlorine-containing agents, such as chlorine gas, chlorinedioxide, or sodium hypochlorite. The present system may include a systemfor on-site generation of chlorine gas as it is needed. Such a system iseconomically beneficial and eliminates the hazards involved intransporting and storing chlorine (either as a gas or liquid) or otherchlorine-containing agent. Sodium hydroxide, a known byproduct of mostindustrial processes for producing chlorine gas, may be used as part ofthe present process or sold for other uses. Preferably, bleaching iscarried out in a separate bleaching step by soaking the bedding in achlorine-containing bleaching solution, and thereafter rinsing thebedding with water. Preferably, bleaching is carried out after at leastone washing cycle, and most preferably after all washing steps arecompleted. The concentration and type of bleaching agent used areselected to achieve the desired level of restored coloration to thebedding, without causing breakdown of the structural integrity of theshavings or like bedding material. The present system preferablycomprises a bleaching agent dispenser adapted to dispense a preselectedamount of a bleaching agent into the first cleaning tank.

If a chlorine bleaching agent is used, both the waste water and beddingare beneficially dechlorinated using a sulfur-based dechlorinatingagent. A preferred agent is sodium thiosulfate, which is relativelybenign and non-toxic. Alternative agents include other thiosulfate saltsor sulfite, bisulfite, and metabisulfite metal salts, preferably of thealkali or alkali earth metals. These agents may be introduced eitherfrom aqueous solution or as solids. The waste water is treated with anamount of dechlorinating agent sufficient to reduce the chlorine orchlorine-containing compounds, including halogenated alkanes, in thewaste stream to environmentally acceptable levels. Preferably, enoughdechlorinating agent is used to substantially neutralize the chlorinecontent. It is also preferred that any residual chlorine bleaching agentin the cleaned bedding material be neutralized to prevent any harm ordiscomfort to animals for whom the recycled bedding is provided.

It is preferred that waste water from the various washing, bleaching,and rinsing steps be collected in one or more waste water holding tanks.The waste water is preferably recycled in a closed loop system tominimize consumption. If needed, the recycled water can be remediated aspart of the process. Some waste water can also be mixed with the manureto create a liquid fertilizer product. Alternatively, the water can bedisposed after any remediation necessary for environmental compliance.

Used chemical tank 14 and used liquid tank provide storage for usedprocess liquids. Suitable processing and remediation may be given theseliquids, to permit them either to be recycled in the continued operationof the present system, used as input for liquefying the removed manureto form fertilizer, or discharged as acceptable effluent.

While the animal waste separated from bedding may be disposed of,burned, or otherwise discarded, it is preferred that it be recycled forsecondary use by processing it into liquid fertilizer or composting.Some or all of the process water used in the present method may beblended with the manure to make liquid fertilizer. Alternatively,composting may be carried out by any suitable technique, includingwindrowing or with in-vessel techniques. In the present process, use ofa mechanical separator to segregate the manure is beneficial forcomposting, as removal of the carbon-rich shavings reduces the ratio ofcarbon to nitrogen in the incoming material, yielding a superior outputcomposted material that does not degrade agricultural soils. Thepresence of the shavings also markedly slows the composting. It isgenerally found that manure by itself will compost in one to two months,whereas mixed material requires three months or more to be fullycomposted. In-vessel techniques are also generally more efficient inpromoting rapid composting than windrowing, and they beneficially reducethe emission of noxious odors. Careful control of temperature andaeration in an in-vessel composting process also reduces the emission ofcertain greenhouse gasses, including methane and other volatile organiccompounds.

The present system can be mounted in a fixed installation. It is alsopossible to dispose the equipment on a trailer or like conveyance,permitting it to be moved to different sites. By moving the equipmentcloser to barns in which the bedding is used, the cost and difficulty oftransporting used bedding is eliminated, and the now-cleaned bedding canbe reused, again without incurring any need to transport it. Inaddition, the need for packaging can often be eliminated, as the cleanedmaterial can be conveniently stockpiled pending use.

Referring to FIGS. 6 and 7 , an embodiment of a processing apparatus isshown. FIG. 6 is a front plan view of a processing assembly forrecycling animal bedding material. FIG. 7 is a side plan view of theprocessing assembly of FIG. 6 . In the depicted implementation of thepresent animal bedding reprocessing process, shown generally at 600, ahopper and conveyer 611 conveys soiled bedding material to be recycledto a first shaker/screener 612 (optionally) that separates the manurefrom the soiled animal bedding. The bedding material falls to an(optional) second shaker 615 that cleans the bedding material,preferably with surfactant. A (optional) third shaker 616 rinses andrestores color. A tank 613 is located below that is appointed to receivegray matter. Preferably, the tank below is approximately 3,700 gallons.Screening plant sprayers are preferably utilized having flow rates of20-40 GPM (gallons per minute) to avoid pulverizing the shavings or losematerial.

Preferably, the dryer is a modified version of a full size dryer.Modification and further design is provided to accommodate smallervenues such as certain horse shows and racetracks with limited meets andcapped numbers of horses.

Combined waste material, manure and/or manure and hay, straw, shavingscombined, is manually loaded (or mechanically loaded) into a dryer drumor vessel in communication with a motor that rotates the drum or vessel.Motors having about 10 horsepower (hp) are utilized for rotating thedrum or vessel. Air intake preferably ranges from about 14″-15″, at400,000 BTU/hr, single phase 120-11.2 amps, variable speeddrive-adjustable 220-33 amps. For example, a motor sold in associationwith the trade name Salamander is contemplated for use. Preferably, a 3phase output 220 is used to drive the motor with adjustable speed driveconversion.

FIG. 8 is a schematic depiction of a processing assembly for recyclinganimal bedding material, shown generally at 800. The processing plantassembly includes a storage facility 801, shavings and bagging building802, dryers 803, and housing for shakers, DAF and tanks at 804 incommunication with material hopper and conveying systems 805. In-vesselcompost units are shown at 806.

Although fuel products discussed hereinabove relate generally to fireproducts, it is noted that the fuel products may be utilized as organicfuel as fertilizer. Still another objective of the present invention isto provide a process and a method for manufacturing an organic fuelbrick or pellets that can be used for fertilizer in pots, directly in agarden, and with one of the components helping to keep moisture aroundplants thereby reducing the need to water the plants use themanufactured logs as fertilizer substitute—preferably as a time releasednutrient source for plants.

The following examples are provided to more completely describe thesystem and method described herein. The specific techniques, conditions,materials, proportions and reported data set forth to illustrate theprinciples and practice of the invention are exemplary only and shouldnot be construed as limiting the scope of the invention.

EXAMPLE

Soiled bedding in the form of wood shavings used in a horse stall andcontaining horse manure is cleaned using a series of washing, rinsing,and bleaching steps. A bag containing approximately 50 gallons of usedbedding is first run through a shaking operation to separate most of themanure from the remaining bedding. A gallon of the soiled bedding fromwhich the manure is substantially removed is then placed in a cleaningvessel having a capacity of about five gallons and there washed in aboutthree gallons of a washing solution comprising water to which aquarter-cup of liquid domestic laundry detergent is added per gallon ofbedding. The soiled bedding is agitated in the solution for 20 minutes.Then the vessel is drained and refilled with two gallons of rinse water.The soiled bedding agitated periodically during a 20 minute rinse cycle.Thereafter, three-quarters of a cup of 12.5% sodium hypochlorite bleachis added to bleach the shavings to substantially restore their originalcolor and appearance and kill pathogens remaining. Alternatively,chlorine gas (about twenty grams per gallon soiled bedding processed) isused as the bleaching agent. After about ten minutes, the bleachingoperation has restored the color of the shavings. Then, sufficientneutralizer in the form of a solution of 3 grams of sodium thiosulfateper gallon of water is added to neutralize the residual chlorine presentfrom the bleach. After neutralization, the characteristic smell ofchlorine is no longer perceptible. Conventional chlorine test strips areused to confirm complete neutralization. The now cleaned and sanitizedbedding is dewatered and heated in an oven held at 350° F. for about onehour to dry it and kill any remaining pathogens. Alternatively, thedrying is carried out for about 2-4 minutes in a rotary drum dryer heldat 600-800° F. for 2-4 minutes.

The resulting bedding material has substantially the same texture,color, and appearance as fresh wood shaving bedding, demonstrating thatit is suitable for reuse as bedding.

In another aspect, a system for reprocessing soiled animal beddingmaterial commingled with manure to form a compacted product is provided.The system comprises in sequence: (a) a first shaker/screener adapted toseparate out at least a preponderance of said manure from said beddingmaterial; (b) a second shaker/screener for cleaning said soiled beddingusing a first cleaning agent; (c) a third shaker/screener for rinsingsaid soiled bedding for a first rinsing period; (d) collecting wastewater resulting from at least one of said washing, rinsing, or drainingsteps in a tank; and (e) drying said bedding to form cleaned recycledbedding material. The process may further comprise one or moreadditional cycles of washing and rinsing and/or a bleaching cycleemploying a bleaching solution of water and a bleaching agent, and arinse thereafter. It is noted that where a compact system is desired,the process can be carried out in a single shaker/screener unit, or twoshaker/screener units. Where just a first shaker/screener is utilized,the (optional) separating step is carried out, followed by overheadspray cleaning or washing and rinsing directly thereafter whereupon aslurry may be formed that is preferably collected in waste tanks forgray material, followed by drying the bedding material. Where twoshakers are utilized, a first shaker/screener separates (optional) themanure from the bedding and a second shaker is used for cleaningfollowed by rinsing, followed by drying of the bedding material. Theseand other aspects of the process are considered to fall within the scopeof the invention.

Having thus described the invention in rather full detail, it will beunderstood that such detail need not be strictly adhered to, but thatadditional changes and modifications may suggest themselves to oneskilled in the art. It is to be understood that the present system andprocess may be implemented in various ways, using different equipmentand carrying out the steps described herein in different orders. Forexample, the bleaching operation might be accomplished between twowashing cycles. All these changes and modifications are to be understoodas falling within the scope of the invention as defined by the subjoinedclaims.

The invention claimed is:
 1. A process for reprocessing soiled animalbedding material composed of wood shavings, commingled with manure toform a product, comprising the steps of: a. separating said soiledbedding material in a shaker to send at least a preponderance of saidmanure to a holding tank; b. washing said separated bedding materialwith water and a surfactant and rinsing thereof in a cleaning tankwherein said separated bedding material is not tightly packed and isable to move around and circulate in the cleaning tank during washingand rinsing, said washing being carried out using an aqueous solutionwith surfactant; c. decontaminating said bedding material by heating anddrying said separated bedding material, wherein said bedding material isheld at a temperature for a time to ensure that any said manureremaining breaks down and any pathogens are killed; and d. packagingsaid product by a bagging system configured to receive said product andpackage it into bags; e. said separation step being the first step ofsaid process and said product, after being packaged, havingsubstantially a same texture, color, and appearance as fresh animalbedding material.
 2. The process as recited by claim 1, furthercomprising the step of composting said separated manure.
 3. The processas recited by claim 1, wherein said product is a recycled beddingmaterial.
 4. The process as recited by claim 1, wherein additives areadded to said bedding material.
 5. The process as recited by claim 4,wherein said additives are added to said bedding material after saidbedding material is dried.
 6. The process as recited by claim 5, whereinsaid additives comprise botanicals.
 7. The process as recited by claim1, comprising the step of sending said soiled bedding to a secondshaker/screener.
 8. The process as recited by claim 1, wherein saidbedding material is held at a temperature for a time sufficient toattain a required moisture level ranging from about 10 to 17%.
 9. In aprocess for treating soiled animal bedding material composed of woodshavings and commingled with manure to form a product comprising thesteps of (i) separating said soiled bedding material in a shaker toremove at least a preponderance of said manure therefrom, (ii) washingsaid separated bedding material with water and a surfactant and rinsingthereof, (iii) decontaminating said bedding material by heating anddrying said bedding material at a temperature and for a time to ensurethat remaining manure breaks down and its pathogens are killed, and (iv)packaging said product by a bagging system configured to receive saidproduct and package it into bags, the improvement wherein saidseparating step comprises the first step of said process, washing iscarried out in a cleaning tank wherein said separated bedding materialis not tightly packed and is able to move around and circulate in thecleaning tank during washing and rinsing, said washing is carried outusing an aqueous solution with surfactant, and said product, after beingpackaged, has substantially a same texture, color, and appearance asfresh animal bedding material.
 10. The process as recited by claim 9,wherein said bedding material is held at a temperature for a timesufficient to attain a required moisture level ranging from about 10 to17%.
 11. In a system for treating soiled animal bedding materialcomposed of wood shavings and commingled with manure to form an endproduct during a process comprising the steps of (i) separating saidsoiled bedding material in a shaker to remove at least a preponderanceof said manure therefrom, (ii) washing said separated bedding materialwith water and a surfactant and rinsing thereof, (iii) decontaminatingsaid bedding material by heating and drying said bedding material at atemperature and for a time to ensure that remaining manure breaks downand its pathogens are killed, and (iv) packaging said product by abagging system configured to receive said product and package it intobags, the improvement wherein said separating step comprises the firststep of said process, washing is carried out in a cleaning tank whereinsaid separated bedding material is not tightly packed and is able tomove around and circulate in the cleaning tank during washing andrinsing, said washing being carried out using an aqueous solution withsurfactant and said product, after being packaged, has substantially asame texture, color, and appearance as fresh animal bedding material.12. The system as recited by claim 11, wherein said end product is afuel product.
 13. The system as recited by claim 11, wherein said endproduct is a recycled bedding material.
 14. The system as recited byclaim 11 wherein additives are added to said bedding material.